Primary battery cell



June 9, 1953 G. A. F. WINCKLER El AL PRIMARY BATTERY CELL Filed June 16, 1949 2 Sheets-Sheet 1 FIG. I

FIG. 3'

FIG.

6207274 4 91%; 017a (lb/742 1 BY ATTORNEYS n 1953 G. A. F. WINCKLER El AL 2,641,623

' PRIMARY BATTERY CELL 7 Filed June 16, 1949 2 Sheets-Sheet 2 FIG. 4

d ATTORNEYS Patented June 9, 1953 A UNITED STATES PATENT OFFlfi'E fl ..2,s41,s2s i PRIMABYBAT'TERY CELL Gunnar A. F. Winckler, Milford, and Otto K. Reinhardt, West'Haven, Conn., assignors to Olin Industries, Inc.

Applicationglune lfi, 1949, SerialNo. 99,448

9 Claims. (cuss-.12)

This invention relates to improvements in pri- -mary cells and'generally to improvements in primary cells using an air-depolarized cathode "with a suitable electrolyte and a metal anode. -'More particularly, this invention relates to improvements in cells functioning by the zinc-al- 'kali-carbon-oxygen electro-chemical system;

While cells of thistype are well known and are particularly suitable for some uses, their use has, in the past, been limited. In the present invention we provide a cell of this type that is very simple and inexpensive to manufacture and that possesses certain advantages over known constructions heretofore proposed, or used.

In carrying out the invention we provide a cathode in the form of a molded cup of .carbonaceous material, thus eliminating the neycessity of an outer casing. The cup is formed of a molded mixture of activated carbon and a plastic binder producing an electrode that is permeable to 'air to permit oxygen to reach the interface between the electrode and the electrolyte and is impermeable to aqueous. solutions, :constituting the electrolyte. The inner-surface '-of the cathode may be partly coated :with airimpermeable material to control the electrical characteristics of the cell. Thus, for w drain applications, such control of the air supplyincreases the active life of the cell.

The anode preferably comprises a'strip of zinc or other metal'bent into U-shape. and secured by molding in a cap which supports the anode within the carbon cup and forms a closure for the cell. Such construction provides increased -metal surface exposed to the electrolyte, thereby providing high flash current and better characteristics on high drain. The use of such an anode in combination with a cathode in Whi-chthe bottom of the cathode cup is active tends to em-- phasize consumption of the bottom of the .zinc electrode thereby decreasing the possibility that the anode will preferentially corrode at the electrolyte line and eventually drop off large portions of unconsumed metal into the bottom-of the cell. i v

The simplified construction in which the anode is molded into the plastic cap permits positive and easy positioning of the metal electrode with- -in the carboncup, eliminates complicatedcon- -nections and also eliminates the use of a bottom washer or the like to prevent internalshort- 'ing of the cell. The cap forms a pressure fit with the top of the carbon cup and by use of "a suitable sealing composition *materially decreases the possibility of leakage. i$uitabletter minals may be molded on the bottom of the carbon cup. y

In the accompanying drawings we have shown. two embodiments of the invention. In this showing:

Fig. lis aplanview; v r i Fig. 2 is avertical, sectional view on line 2"'2 ofFig.1; Fig. 3 is a similar view on line 33 of Fig. 2;

Fig. 4 is a plan view. partslshown in section, of another form of the invention Fig. 5 is a side elevation, parts shown inf-section, of the cell shown in Fig.4;

Fig. 6 is a verticalsectional view; and Fig. 7 is a horizontahsectional view on] line 1' 1 of i 6; 1 4:1; Referring to the drawings the reference numeral. I designates generally the 'carbon cup. The cup is formed of a suitable moldable -mix ture' ofactivated 5 carbon and a plastic binder which will produce an electrode having the-deethyl cellulose.

sired characteristics. It must be permeable to air to permit the oxygen from the air to reach the interface between the carbon electrode and the contained electrolyte. It must also be impermeable to the electrolyte solution as otherwise the pores or spaces in the carbon become filled with electrolyteand thus block ofi the -admission of air.

In forming the carbon cup we employ a mixture of activated carbon and a suitable binder, such as Polystyrene, polyvinyl chloride,

' or other plastic material, which is resistantto decomposition by the electrolyte and which is 1 ing mixture.

dried; However, suitable cups may also be made by a hot low pressuremolding process, in the also not wetted by the electrolyte, may be used in place of ethyl cellulose. The amount 1 of binder employed may be varied and, in general,

vated carbon gives a satisfactory cup. Ethyl acetate may be employed as a solvent for the binder and a trace of lubricating oil added to the mold- The cup is molded cold and air absence of a volatile solvent.

The cell, of course, may be of any desired size and shape and as illustrated, it is oval in horizontal cross section consisting of 'frontand back walls zandffi'and rounded endsfd. :The walls are joined by a bottom on which buttons '6, serving as terminals, may be molded. At its upper edge the thickness of the wall of the cup may be decreased as indicated at I and the face or outer surface 8 of this upper portion may be tapered to facilitate assembly of the positive cap.

The zinc electrode 9 is formed of a single sheet or, strip of zinc which is bent into U-shape forming a pair of legs I0. At the bottom of the U, the strip is headed, as shown at H in Fig. 2 of the drawings, to permit it to be assembled with a plastic cap with a portion of therzinc electrode exposed at the top of the cell to functionas a terminal.

forms a pressure fit over the carbon cup andthe.

engaging surfaces are provided with ;a seal of a. rubber cement-polyvinyl chloride solution, or

the like.

The constructionheretofore described pro- 'duce yacomplete and operative cell. However, air depolarized cells .havingan alkaline elec- .trglyte, once exposedto air, become inoperative within a certainperiod-of time whether or not the cell is in use throughout the entire period.

:It 'is; thereforedesirable, in someinstances, to-

control the permeability of the carbon electrode .toair-.to; increase the effective life of the cell. ,Thismis particularly. true when the cell is-used .for'low drain application. In such instances, a portion of the interior surface of the carbon electrode may be coated with aplastic binder im- ;permeable-to air to decrease. the area ofthe interface between the electrolyte andthe cathode. In the drawings, we have illustrated a plating l6 formed by electroplating the exterior surface of a: portion ofthe carbon cup with metal. As shown,.0pen'ings or Windows. IT, are provided in the plating'on opposite sides ofthe cell to permit access of air. Instead of electroplating, the metal coat-ing'may be sprayed, or a thin metal shell may be employed-inwhich the carbon electrode is snugly received. Preferably, thecontact ,between the metal coating and the cup is.an in- ;timate one, such asis obtained when the coating is electroplated, in order tofobtain optimum-elec-- coating may be applied to the exterior of the carbon cup to normallycover the. openings "or win- :dows H in the casing. This strip may be .retained on'the cell-until it is actually ready for 1; use and if thecell isto be used intermittently, it may beremoved sufiiciently to uncover one or both of the windows ll'while the cell iszin active .use and replaced during intervals when the cell is not in active use. V

Referring to Figs. 4 to '7 of the drawingsythe reference numeraldesignates a carbon cup which may be prepared as heretofore described but which, as shown .in Figs.i4 to 7, is circular "in cross section and represents a cell of the size known as the AAsize. This cup may be molded of activated carbon and a suitable binder in :the 2 manner heretofore described. and is provided with As shown, the legsfjlfl' are parallel, but they may be bent towardeach ;other'to in.-1

I If desired, the. electrolyte may be immmob'ilized by known means, forexample, by thee-addition of a suitable absorbent or byithe. additionof a a bottom 26 having a button 2'! formed therein to serve as a lower terminal. The upper end 28 of the wall of the cup is decreased in thickness as heretofore described for the reception of the cap or closure. An anode 29 formed of zinc or other metal is arranged in the cup. As in the form of the invention heretofore described, the .anode. is formediof a single sheet or strip of metal which isbent into a U-shaped member forming the two legs and is headed, as indicated at 30 at the bottom of the U, to permit it to be assembled .with a plastic cup. The legs, as shown in Fig. 7,

are, in'this instance, shaped into arcs in horizzontalcross section so that the anode is substantially equallyspaced from the inner wall of "the carbon cup *throughout the entire cell.

Spaces 3 Lareformed between the adjacent edges of the two legs of the anode and the legs may be-provided with spaced openings (not shown) similar to the openings IZ in the form of the in -vention shown? in :Eigs. 11 to 5,3 ;;of -;the,;drawings.

The. anode is: insert-molded; intoramlastic cup the nuteizsurfacezof .the top 28: of the carbon gagingsurfaces are-providedwith-a seal 34 of rubber cement,:po-lyvinylrchlo-ride solution, .orjthe like.

To control thepermeability o-fthe carbon electrode'toxair'toLincrease the eifective life of the cell;:portions of; the interior surfacerof the carbon r electrodev may" be .:coated with a plastic binder impermeable .to :airzto decrease the area'of the .interface between;therelectrolyte"and the cathode. aAs heretofore described, 1theouter surface of the cathode .may .beprovidedwithsa metal 'jacket; 35 formedinany of the ways heretofore "described. This :metal jacketmay have one .or

moreopenings. 36 tocpermitaccess Of'fail'. These openings maybe .placedzatganyxdesired .point: and

- are illustrated in. thebottom .of the jacket in this form of the inventionlsee-Figfi). ,If' the electrode is.cprovide'd with the openings 1 2,..thezpaper liner is, of course; provided with registerin'gopentrcly-te lis placed in thezcup as indicatedat' I9.

suitable starch or gum. vWhen astarch or gum is used to immobilizethe-electrolyte,'itis advantageous to coverthe meta'l electrode -with a sheet 7 paper liner, since shrinkage of I the: gelled electrolyte is then offset by swelling'of; the paper. Such a liner is shown at 31 inFigs. 5 to 7 of the drawings.

It may at times be advantageous to use electrolytes other than an alkali solution =-For -eX- ample, salt solutions such as ammonium chloride,

with "or without other chlorides" such asiof' -zinc,

or a solution of an alkali or alkaline-earth halide, may be used. When the anode metal consists of magnesium, the electrolyte: preferably consists of a solution of magnesium bromida-orthebromide of'some other alkali or alkaline+earth metal, containing a small amount of an alkali chromate as inhibitor.

his to be understood-thatathe. aboveedescribed V cathode constructionmaytbe appliedzto .other electrode elements capable ofxdepolarization by gaseousoxygen. :Eorexainple, theactiva-tsd carbon may have admixed therewith significant amounts of metallic oxides or salts such as oxides of manganese or permanganates.

The simplicity of the cell will be apparent from the foregoing description. The carbon cups are molded as heretofore described and, if desired, plated to form the shell 16 or placed or molded in a preformed metal can. The electrolyte is then placed in the cup to the proper level and the upper edge 8 of the cup wiped with a rubber cement or polyvinyl chloride solution, or the like after the interior of the plastic top has been coated with the same in order to prevent creepage of the electrolyte. The preformed anode and plastic cap is then assembled with the cup, the anode being placed in the cup as shown, and the cap forming a pressure fit over the top of the cup. If the strip I8 is employed, it is then placed on the completed cell.

The coating applied to portions of the interior surface of the cathode cup, for controlling the permeability of the cathode to air, may be asphalt, shellac, varnish, other resinous coatings, or other similar material,

In either form of the invention the anode may be amalgamated in known .manner before assembly with the cap.

The claims of the application are directed to the construction of the cathode of the cell. Claims directed to the anode form the subject matter of cup formed of a molded mixture of air depolarized carbon and ethyl cellulose, the ethyl cellulose comprising about 15 percent by weight of the mixture, the cup being air permeable, substantially liquid free and resistant to penetration by alkaline solutions and forming a container for an alkaline electrolyte and a U-shaped zinc anode, and a cap of molded plastic material forming a closure for the cup, the anode being molded into the cap.

2. A cathode for an air-depolarized cell comprising a substantially dry, porous cup formed of a molded mixture of an air-depolarized cathode material and a water-repellent binder, the amount of the binder in the molded mixture being such that the cup is air-permeable but is impermeable to electrolyte, said cup being adapted to form a container for a metal anode and an electrolyte solution.

3. A cathode as defined in claim 2 in which a portion of the interior surface of the cup has a coating impervious to air.

4. A cathode as defined in claim 2 in which the cup has a metallic coating covering a portion only of the exterior thereof.

5. A cathode as defined in claim 2 in which the molded mixture includes a substantial amount of carbon.

6. A cathode as defined in claim 2 in which the molded mixture consists essentially of carbon andethyl cellulose.

7. A cathode as defined in claim 6 in which the amount of ethyl cellulose in the molded mixture constitutes approximately 15% thereof by weight.

8. An air-depolarized battery cell comprising a cathode formed of a substantially dry, porous cup of a molded mixture of an air-depolarized cathode material and a water-repellant hinder, the amount of binder in the molded mixture being such that the cup is air-permeable but is impermeable to electrolyte, a body of electrolyte in said cup, and a metal anode within said electrolyte.

9. An air-depolarized battery cell as defined in claim 8 in which the molded mixture consistsessentially of carbon and ethyl cellulose and the amount of the ethyl cellulose constitutes approximately 15% of the weight of the molded mixture.

. GUNNAR A. F. WINCKLER. OTTO K. .REINI-IARDT.

References Cited in the file of this patent UNITED STATES PATENTS OTHER REFERENCES Morgan, et al., Industrial and Engineering Chemistry, Feb. 1946, page 219. 

2. A CATHODE FOR AN AIR-DEPOLARIZED CELL COMPRISING A SUBSTANTIALLY DRY, POROUS CUP FORMED OF A MOLDED MIXTURE OF AN AIR-DEPOLARIZED CATHODE MATERIAL AND A WATER-REPELLENT BINDER, THE AMOUNT OF THE BINDER IN THE MODLED MIXTURE BEING SUCH THAT THE CUP IS AIR-PERMEABLE BUT IS IMPERMEABLE TO ELECTROLYTE, SAID CUP BEING ADAPTED TO FORM A CONTAINER FOR A METAL ANODE AND AN ELECTROLYTE SOLUTION. 